Method of making protective shield for external electrical parts of a control arrangement

ABSTRACT

A combination of a control arrangement and a protective shield, the protective shield and methods of making the same are provided, the combination comprising a control arrangement having a housing unit provided with certain external electrical parts and a one-piece protective shield carried by the housing unit and having a section thereof covering the certain external electrical parts. The section of the protective shield is movable relative to the remainder of the shield between a first position thereof that covers the certain external electrical parts and a second position thereof that uncovers the certain external electrical parts.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional patent application of its copendingparent patent application, Ser. No. 627,047, filed July 2, 1984, nowU.S. Pat. No. 4,554,616.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a new protective shield for the externalelectrical means of a control arrangement and to a method of making suchprotective shield as well as to a combination of a control arrangementand such protective shield and to a method of making such a combination.

2. Prior Art Statement

It is known to provide a combination of a control arrangement havinghousing means provided with certain external electrical means and aone-piece protective shield carried by the housing means and having asection thereof covering the certain external electrical means. Forexample, see the Place, U.S. Pat. No. 3,621,197; the Them et al, U.S.Pat. No. 3,626,151; the Stearley, U.S. Pat. No. 3,914,660 and theManecke et al, U.S. Pat. No. 3,914,661.

SUMMARY OF THE INVENTION

It is one feature of this invention to provide a new protective shieldfor covering certain external electrical means of the housing means of acontrol arrangement.

In particular, it was found according to the teachings of this inventionthat prior known protective shields must be completely removed fromtheir respective control arrangements in order to provide access to theexternal electrical means of the control arrangement for servicingpurposes and the like whereby the removed protective shield must bereplaced on the control arrangement after access has been made to theexternal electrical means.

However, it was found according to the teachings of this invention thata one-piece protective shield can be provided with a movable sectionthat can be moved between a position thereof that covers certainexternal electrical means of the control arrangement and a positionthereof that uncovers the certain external electrical means forservicing purposes and the like so that the protective shield need notbe removed from the control arrangement to provide access to thosecertain external electrical means thereof.

For example, one embodiment of this invention provides a combination ofa control arrangement having housing means provided with certainexternal electrical means and a one-piece protective shield carried bythe housing means and having a section thereof covering the certainexternal electrical means, the section of the protective shield beingmovable relative to the remainder of the shield between a first positionthereof that covers the certain external electrical means and a secondposition thereof that uncovers the certain external electrical means.

The protective shield is substantially flat when the section is in thefirst position thereof, the section of the protective shield beingsubstantially transverse to the remainder of the shield when the sectionis in the second position thereof. The protective shield has hinge meansthat hinge the section to the remainder of the protective shield, thehinge means having means that holds the section in the first positionthereof when the section is moved to the first position thereof and thatholds the section in the second position thereof when the section ismoved to the second position thereof.

Accordingly, it is an object of this invention to provide a newcombination of a control arrangement and a one-piece protective shield,the new combination of this invention having one or more of the novelfeatures of this invention as set forth above or hereinafter shown ordescribed.

Another object of this invention is to provide a method of making such anew combination, the method of this invention having one or more of thenovel features of this invention as set forth above or hereinafter shownor described.

Another object of this invention is to provide a new protective shieldfor a control arrangement, the protective shield of this inventionhaving one or more of the novel features of this invention as set forthabove or hereinafter shown or described.

Another object of this invention is to provide a method of making such aprotective shield, the method of this invention having one or more ofthe novel features of this invention as set forth above or hereinaftershown or described.

Other objects, uses and advantages of this invention are apparent from areading of this description which proceeds with reference to theaccompanying drawings forming a part thereof and wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view illustrating the new combinationof this invention that comprises a control arrangement and a one-pieceprotective shield therefor.

FIG. 2 is an enlarged front perspective view of the protective shield ofFIG. 1.

FIG. 3 is an enlarged front view of the protective shield of FIG. 1.

FIG. 4 is a view similar to FIG. 3 and illustrates the rear side of theprotective shield of FIG. 1.

FIG. 5 is a cross-sectional view taken on line 5--5 of FIG. 3 andillustrates a fragmentary portion of the housing means of the controlarrangement of FIG. 1 in order to illustrate how the protective shieldis secured to the housing.

FIG. 6 is a perspective view of the protective shield of FIG. 1 with oneof the sections thereof disposed in its uncovering position.

FIG. 7 is a fragmentary cross-sectional view taken on line 7--7 of FIG.6.

FIG. 8 is a view similar to FIG. 6 and illustrates another section ofthe protective shield of FIG. 1 in its uncovering position.

DESCRIPTION OF THE PREFERRED EMBODIMENT

While the various features of this invention are hereinafter illustratedand described as being particularly adapted to provide a protectiveshield for the control arrangement for a water heater, it is to beunderstood that the various features of this invention can be utilizedsingly or in various combinations thereof to provide a protective shieldfor control arrangements for other apparatus as desired.

Therefore, this invention is not to be limited to only the embodimentillustrated in the drawings, because the drawings are merely utilized toillustrate one of the wide variety of uses of this invention.

The new combination of applicant's invention is generally indicated bythe reference numeral 20 in FIGS. 1 and 5 and comprises a controlarrangement that is generally indicated by the reference numeral 21 foran electrically operated water heater tank 22 and a one-piece protectiveshield 23 that is carried by a housing means 24 of the controlarrangement 21 and has a first section or end 25 for covering certainexternal electrical means 26 of the housing means 24 and another sectionor end 27 for covering other external electrical means 28 of the housingmeans 24 so as to tend to prevent contact with the external electricalmeans 26 and 28 when an operator is adjusting a temperature settingcontrol knob 29 of the control arrangement 21 that is exposed at a firstopening means 30 formed through the protective shield 23 or is operatinga reset means 31 of the control arrangement 21 that is exposed atanother opening means 32 formed through the protective shield 23.

Such general combination of a protective shield and a controlarrangement and the reasons for the same are fully set forth in theaforementioned U.S. Pats., Nos. 3,621,197; 3,626,151; 3,914,660 and3,914,661 whereby these four U.S. Pats. are being incorporated into thisdisclosure by this reference thereto.

While the control arrangement 21 can comprise any suitable structure,the same includes a first control device 33 having temperature operatedelectrical switch means (not shown) in a housing 34 thereof forcontrolling the electrical connection between an electrical power source(not shown) and an electrical heater means (not shown) that has anexternal portion of its housing means 35 forming part of the controlarrangement 21 and being electrically interconnected to the controldevice 33 by suitable external leads (not shown), the control device 33being likewise interconnected to the electrical power source byelectrical leads (not shown). Such electrical leads in combination withthe electrical terminals 36 and 37 of the housings 34 and 35 comprisethe external electrical means 26 and 28 of the control arrangement 21that are to be covered by the sections 25 and 27 of the protectiveshield 23 when the shield 23 is secured to the housing means 24 in amanner hereinafter set forth whereby the bared ends of such leads forconnection to the terminals 36 and 37 as well as the terminals 36 and 37will be covered by the sections 25 and 27 of the protective shield 23when the sections 25 and 27 are disposed in their covering positions aswill be apparent hereinafter.

The protective shield 23 of this invention comprises a one-piecestructure formed of any suitable material, such as plastic materialsuitably molded into the configuration illustrated and hereinafterdescribed. For example, one working embodiment of the protective shield23 of this invention is formed by molding a polypropylene sold byHercules Incorporated of Wilmington, Del. as "Hercules No. 6524Red".Such protective shield 23 has a width of approximately 1.750 inchesand an overall length of approximately 6.125 inches with the main bodyof the protective shield 23 being approximately 0.062 of an inch thickexcept at the peripheral edge thereof which is approximately 0.125 of aninch.

However, it is to be understood that the protective shield 23 of thisinvention can be formed of any suitable material and have any suitabledimensions as long as the same functions in the same manner as theprotective shield of this invention as hereinafter described.

The protective shield 23 has an intermediate part 38 that has one end 39hinged to one end 40 of the section 25 by integral hinge means that isgenerally indicated by the reference numeral 41. The other end 42 of theintermediate part 38 is hinged to an adjacent end 43 of the section 27by similar integral hinge means that is also generally indicated by thereference numeral 41.

The outer peripheral edge of the protective shield 23 is defined by anupstanding flange 44 of the protective shield 23 and extends outwardlyfrom a substantially flat front side 45 of the shield 23.

Two spaced apart projections 46 extend from the substantially flat rearside 47 of the protective shield 23 and are one-piece and integral withthe intermediate part 38 thereof, each projection 46 having an enlargedbifurcated end 48 and a smaller substantially cylindrical intermediatepart 49.

The housing means 24 of the control arrangement 21 has a pair of spacedapart stepped openings 50 formed therein with the smaller substantiallycylindrical portions 51 of the openings 50 interrupting an outer flatside 52 of the housing 34 of the control device 33 and having largercylindrical portions 53 respectively adapted to snap fittingly receivethe enlarged ends 48 of the projections 46 when the same are insertedinto the aligned openings 50 in the manner illustrated in FIG. 5 wherebythe resulting shoulders 54 located between the enlarged ends 48 andintermediate parts 49 of the projections 46 will lock in abuttingrelation against the respective cooperating shoulders 55 defined by thejunctures between the enlarged parts 53 and reduced parts 51 of theopenings 50. In this manner, the protective shield 23 is adapted to bedetachably secured to the housing means 24 of the control arrangement 21so as to be in substantially a normally non-removable conditiontherewith.

However, because the sections 25 and 27 of the protective shield 23 arerespectively hinged to the intermediate part 38 of the protective shield23, the same can be selectively moved out of their normal coplanarcondition with the intermediate part 38 as illustrated in FIGS. 1, 2, 3,4 and 5 to positions that are disposed substantially transverse theretoas illustrated respectively in FIGS. 6 and 8 so as to respectively bemoved from their covering positions to their uncovering positions forproviding access to the external electrical means 36 and 37 of thecontrol arrangement 21 when desired. Thereafter, the sections 23 and 27can be moved back from their uncovering condition as illustratedrespectively in FIGS. 6 and 8 to their fully covering positions whereinthe same are disposed substantially flat and coplanar with theintermediate part 38 so as to define a substantially flat coveringstructure for the control arrangement 21 in a manner not provided by theprotective shields in the aforementioned four U.S. Pats. wherein theprotective shields must be completely removed from their respectivecontrol arrangements in order to provide access to the externalelectrical means thereof.

Each hinge means 41 of the protective shield 25 includes a V-shapedrecess 56 formed in the rear side 47 of the protective shield 23 anddefining a substantially straight hinge line 57 extending from one sideedge 58 of the protective shield 23 to the other side edge 59 thereof,the hinge line 57 being interrupted by a slot means 60 formed mediallybetween the side edges 58 and 59. The slot 60 for the hinge means 41between the intermediate part 38 and the section 27 is joined with theopening means 30 that passes through the intermediate part 38 asillustrated.

Each hinge means 41 includes a pair of spaced apart toggle members 61each being molded so that the same has opposed free side edges 62 and 63and opposed ends 64 and 65 respectively hinged by hinge lines 66 and 67defined by recesses 68 and 69 respectively formed in the rear side 47 ofthe protective shield 23 and in post means 70 extending in an angularmanner from the front side 45 of the intermediate part 38 of theprotective shield 23.

The toggle members 61 function in a spring-like manner to hold therespective section 25 or 27 in either its covering position asillustrated in FIG. 5 or in its uncovering condition as illustrated inFIG. 7 by being bowed in the manner illustrated in FIG. 5 so that thesame are over center on the front side 45 of the protective shield 23 orbowed so as to be over center on the rear side 47 of the protectiveshield 23 as illustrated in FIG. 7.

In this manner, the toggle members 61 act as spring means that tend tohold the sections 25 and 27 either in their full covering position asillustrated in FIG. 5 or in their full uncovering position asillustrated in FIGS. 6 and 8 while the hinge lines 57 of the hinge means41 readily permit the sections 25 and 27 to be moved between theircovering and uncovering positions in a manner well known in the plasticart as "living hinges".

In order to permit such movability of the sections 25 and 27, theannular flange 44 of the protective shield 23 is provided with V-shapedrecesses 71 on the side 45 of the protective shield 23 in mirror imageto the recesses 56 in the rear side 47 thereof.

Thus, it can be seen that the protective shield 23 of this invention canbe formed in a relatively simple manner by the method of this inventionby merely molding suitable plastic material into the one-piececonfiguration illustrated in the drawings whereby the resulting moldedprotective shield 23 can have the sections 25 and 27 thereof either heldin their coplanar covering position as illustrated in FIG. 5 or held intheir fully uncovering position as illustrated in FIGS. 6 and 8 by theintegral toggle members 61 thereof.

After the protective shield 23 has been made in the above manner, thesame is adapted to be utilized with the control arrangement 21 in amanner now to be described.

When the control arrangement 21 has been operatively interconnected tothe water heater tank 22 as illustrated in FIG. 1 in a manner well knownin the art, such as set forth in the aforementioned four U.S. Pats., theprotective shield 23 of this invention can be secured thereto in themanner illustrated in FIG. 1 by inserting the projections 46 of theprotective shield 23 into the openings 50 in the housing 34 of thecontrol device 33 whereby the enlarged ends 48 thereof will be snapfitted into the enlargements 53 of the openings 50 to have the shoulders54 thereof hook against the shoulders 55 of the housing means 34 andthereby secure the protective shield 23 to the housing means 24 of thecontrol arrangement 21 with the rear side 57 of the intermediate part 38of the protective shield 23 held against the flat surface 52 of thecontrol device 33 whereby the sections 25 and 27 of the protectiveshield 23 when disposed in the coplanar position illustrated in FIGS. 1and 5 will fully cover from the front of the control arrangement 21 theexternal electrical means 26 and 28 and will be held in such coveringpositions by the toggle members 61 as the same are disposed in theirover center position on the front side of the front surface 45 of theprotective shield 23.

However, should an operator desire to reach or otherwise have access tothe certain external electrical means 26 of the control arrangement 21,that person merely grasps the section 25 of the protective shield 23 andfolds the same outwardly to the position illustrated in FIGS. 6 and 7whereby the section 25 folds on the hinge line 57 and the toggle members61 snap over center from their forwardpositions illustrated in FIG. 5 totheir rear positions illustrated in FIG. 7 wherein the same are disposedbeyond the rear side 57 of the section 23 to hold the section 25 in itsuncovering position as illustrated in FIGS. 6 and 7 which issubstantially transverse to the intermediate part 38 of the shield 23.

After access has been made to such uncovered certain external electricalmeans 26, the operator then moves the section 25 from its uncoveringposition of FIGS. 6 and 7 back to its covering position as illustratedin FIG. 5 as the section 25 will unfold on its hinge line 57 back intoits coplanar position with the intermediate part 38 and the togglemembers 61 will snap back over center from their rear condition asillustrated in FIGS. 6 and 7 to their forward positions as illustratedin FIG. 5 so as to hold the unfolded section 25 in its coplanar andcovering position as illustrated in FIG. 5 and thereby tend to preventaccidental access to the certain external electrical means 26.

Should it be desired to provide access to the other external electricalmeans 28 of the control arrangement 21, the other section 27 of theprotective shield 23 can be moved from its covering position asillustrated in FIG. 5 to its uncovering position illustrated in FIG. 8as the same will fold on the fold or hinge line 57 of its hinge means 41and the toggle members 61 thereof will move or snap from their forwardpositions as illustrated in FIG. 5 in a manner to be over center beyondthe rear side 47 of the section 27 to hold the section 27 in itsuncovered position as illustrated in FIG. 8 wherein the same issubstantially transverse to the intermediate part 38 of the shield 23.After such access has been made to the external electrical means 28, theoperator then can move the section 27 of the shield 23 back to itscovering and coplanar position as illustrated in FIG. 5 and the togglemembers 61 will snap from their rear condition to their front conditionas illustrated in FIG. 5 and thereby hold the section 27 in its coveringcondition until it is desired to again move the section 27 to itsuncovering condition in the manner previously set forth.

Therefore, it can be seen that the one-piece shield 23 of this inventionwill always have its intermediate part 38 secured to the housing means24 of the control arrangement 21 and the sections 25 and 27 can beselectively moved relative thereto between their covering and uncoveringpositions with the toggle members 61 holding the same in the desiredcovered or uncovered position thereof as the case may be.

While the hinge means 41 of this invention can be formed in any suitableconfiguration and dimensions to provide the aforementioned action, inthe previously mentioned working embodiment of the protective shield 23of this invention, it has been found that the toggle members 61 can eachhave a length of approximately 0.984 of an inch between their respectivehinge lines 66 and 67 with a width of approximately 0.219 of an inch.The thickness of the hinge lines 66 and 67 for the toggle members 61 canbe approximately 0.010 of an inch while the hinge lines 57 of the hingemeans 41 can be approximately 0.020 of an inch.

Therefore, it can be seen that this invention not only provides a newprotective shield and method of making the same, but also this inventionprovides a new combination of such a protective shield and a controlarrangement and method of making the same.

While the forms and methods of this invention now preferred have beenillustrated and described as required by the Patent Statute, it is to beunderstood that other forms and method steps can be utilized and stillfall within the scope of the appended claims wherein each claim setsforth what is believed to be known in each claim prior to this inventionin the portion of each claim that is disposed before the terms "theimprovement " and sets forth what is believed to be new in each claimaccording to this invention in the portion of each claim that isdisposed after the terms "the improvement" whereby it is believed thateach claim sets forth a novel, useful and unobvious invention within thepurview of the Patent Statute.

What is claimed is:
 1. In a method of making a combination of a control arrangement having housing means provided with first and second external electrical means thereon and a one-piece protective shield carried by said housing means and having a first section thereof covering said first external electrical means, the improvement comprising the steps of forming said first section of said protective shield to be movable relative to the remainder of said shield betweena first position thereof that covers said first external electrical means and a second position thereof that uncovers said first external electrical means, forming said protective shield to be substantially flat when said first section is in said first position thereof, forming said first section of said protective shield to be substantially transverse to said remainder of said shield when said first section is in said second position thereof, forming said protective shield to have hinge means that hinge said first section to said remainder of said protective shield, and forming said protective shield to have a second section thereof covering said second external electrical means and be movable relative to the remainder of said shield between a first position thereof that covers said second external electrical means and a second position thereof that uncovers said second external electrical means.
 2. A method as set forth to claim 1 and including the steps of forming said protective shield to be substantially flat when said sections are respectively disposed in said first position thereof and to have an intermediate part thereof separating said sections from each other, forming said intermediate part of said shield to have securing means that secures said shield to said housing means, forming said intermediate part to have opening means passing therethrough, and forming said housing means to have manually operable control means aligned with said opening means so as to be accessible at said opening means.
 3. A method as set forth in claim 2 and including the steps of forming said housing means to have socket means, and forming said securing means of said shield that secures said shield to said housing means to comprise projection means received in said socket means.
 4. A method as set forth in claim 1 and including the steps of forming said protective shield to comprise polypropylene, and forming said sections to comprise end sections of said shield.
 5. In a method of making a protective shield for a control arrangement having housing means provided with first and second external electrical means thereon, said method comprising the step of forming said protective shield to be one-piece and be adapted to be carried by said housing means and have a first section thereof covering said first external electrical means, the improvement comprising the steps of forming said first section of said protective shield to be movable relative to the remainder of said shield between a first position thereof that is adapted to cover said first external electrical means and a second position thereof that is adapted to uncover said first external electrical means, forming said protective shield to be substantially flat when said first section is in said first position thereof, forming said first section of said protective shield to be substantially transverse to said remainder of said shield when said first section is in said second position thereof, forming said protective shield to have hinge means that hinge said first section to said remainder of said protective shield, and forming said protective shield to have a second section thereof adapted to cover said second external electrical means of said housing means and be movable relative to the remainder of said shield between a first position thereof that is adapted to cover said second external electrical means and a second position thereof that is adapted to uncover said second external electrical means.
 6. A method as set forth in claim 5 and including the steps of forming said protective shield to be substantially flat when said sections are respectively disposed in said first positions thereof and to have an intermediate part thereof separating said sections from each other, forming said intermediate part of said shield to have securing means that is adapted to secure said shield to said housing means, and forming said intermediate part to have opening means passing therethrough adapted to be aligned with manually operable control means of said housing means.
 7. A method as set forth in claim 6 and including the step of forming said securing means of said shield that is adapted to secure said shield to said housing means to comprise projection means that is adapted to be received in socket means of said housing means.
 8. A method as set forth in claim 5 and including the steps of forming said protective shield to comprise polypropylene, and forming said sections to comprise end sections of said shield. 